Apparatus and method for making cobble-like blocks

Abstract

A molding tray and system for making molded structures using a moldable material. The molding tray includes an outer tray and a resilient inner mold fitted therein. The outer tray includes a hole in a bottom wall thereof to provide access to a bottom face of the inner mold such that pressure may be applied to the bottom face through the hole so as to dislodge a molded structure.

1. A system for making molded structures, the system comprising a molding station for filling successive molds with a moldable mixture, an input conveying system for conveying empty molds to said molding station and an output conveying system for conveying filled molds away from said molding station, said molding station comprising a mold feeder having a feeder opening and a mold support for positioning and supporting said molds at said opening during filling, said opening comprising an inner door and an outer door displaceable in a plane substantially parallel to said opening, a combined activation of said doors controlling a flow of the mixture from said feeder to said molds, wherein, when said molds have been filled and both said inner door and said outer door are closed, said outer door may be reopened to smooth an open surface of the mixture in the mold, wherein said successive molds each comprise a solid outer tray and a resilient inner mold fitted therein, said outer tray comprising at least one hole in a bottom wall thereof providing access to a resilient bottom face of said inner mold such that a pressure may be applied to said bottom face of said inner mold through said hole(s) so as to dislodge a molded material from filled molds, said system further comprising a station for unmolding molds that have been filled, said station comprising means for seizing said outer tray and inner mold while retractable members are moved to apply pressure to said bottom face of inner mold through said hole(s) so as to dislodge said molded material. 
     
     
       2. The system of  claim 1 , wherein the molded material is cement-based.